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IR lamp control module - HELCON 11XX series -
Smitec S.p.A., viale Vittorio Veneto 4, 24016 San Pellegrino Terme (BG), Italy, www.smitec.it
Installation, use and maintenance manual
BEFORE USING THE MODULES OF THE HELCON 11XX SERIES, YOU MUST READ
THIS INSTALLATION AND USE MANUAL CAREFULLY AND FOLLOW ALL THE INDI-
CATIONS TO GUARANTEE THE MAXIMUM SAFETY
CONTROL MODULE IR LAMPS
The technical data and the drawings in this manual might have been modified later; always
refer to the latest version.
Ver. 1.02
HELCON 11XX SERIES
Installation, use and maintenance manual - EN
1
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Related Manuals for Smitec HELCON 10 Series
Summary of Contents for Smitec HELCON 10 Series
- Page 1 IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN Smitec S.p.A., viale Vittorio Veneto 4, 24016 San Pellegrino Terme (BG), Italy, www.smitec.it Installation, use and maintenance manual BEFORE USING THE MODULES OF THE HELCON 11XX SERIES, YOU MUST READ...
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Page 2: Table Of Contents
IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN Summary 1 Preface ............................... 3 1.1 Main differences between the HELCON 10XX and HELCON 11XX series ........3 2 General warnings ............................4 3 Safety instructions ............................ 6 3.1 General information .......................... -
Page 3: Preface
IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN 1 Preface This manual provides all necessary information for the installation, use and maintenance of the control module IR lamps HELCON 11XX series. The instructions included in this manual are addressed to the following professionals: User is a person, a company or an institution that buys the equipment and User uses it for the purposes it was designed for. -
Page 4: General Warnings
MANUAL. THE EQUIPMENT MUST BE USED FOR PURPOSES DIFFERENT THAN THE ONES DESCRIBED IN THIS MANUAL; SMITEC S.p.A. SHALL NOT BE HELD RESPONSIBLE FOR ANY DAMAGES, INCON- VENIENCES OR ACCIDENTS DUE TO THE NON-COMPLIANCE WITH THESE PRESCRIPTIONS. In order to make the manual consultation easier, the following symbols have been adopted: Indication of “PROHIBITED ACTION”. - Page 5 IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN The symbol “USE OF INDIVIDUAL PROTECTIONS” means that protective gloves must be worn. The symbol “USE OF INDIVIDUAL PROTECTIONS” means that protective glasses must be worn.
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Page 6: Safety Instructions
It is absolutely forbidden to use the equipment for different purposes than the ones de- scribed in this manual. The technical data and the drawings in this manual might have been modified later; always refer to the latest version. All upgrades can be requested to SMITEC S.p.A. directly. -
Page 7: Precautions Against The Risk Of Electrocution
IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN 3.3 Precautions against the risk of electrocution The main power connector is subjected to high voltages during module operation; pay at- tention (danger of electrocution). During all phases of installation and maintenance of the equipment, disconnect it safely from the power supply network. -
Page 8: Technical Data
HELCON module produced at the date of writing of this document. With the aim of technologically improving or updating the product, SMITEC S.p.A. reserves the right to change the technical characteristics of the HELCON module without prior notice. -
Page 9: Electrical Characteristics
IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN 4.2 Electrical characteristics ÷ Main power supply voltage 400VAC -10% 480VAC +5% Type of power supply 2PH 50/60 HZ Maximum short-circuit current 5 kA at the point of installation Current main power consumption 63.8A Model: HELCON 1110... -
Page 10: Mechanical Specifications
IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN 4.3 Mechanical specifications 4.3.1 Weight The following table shows the weight of the various models: Type Weight (kg) KZ010604 14.1 kg KZ010605 15.0 kg 4.3.2 Dimensions External measurements of the only device: Ver. -
Page 11: Order Codes
IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN 4.4 Order codes Order code Model Description IR 400V single-phase lamps control module with 8ch x 3kW, max KZ010604 HELCON 1108 24kW total. IR 400V single-phase lamps control module with 10ch x 3kW, KZ010605 HELCON 1110 max 25.5kW total. -
Page 12: Installation And Commissioning
IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN 5 Installation and commissioning 5.1 Preliminary operations Before putting the device into service, check the following: • verify the perfect integrity of the unit and its components •... -
Page 13: Mechanical Assembly
IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN 5.2 Mechanical assembly 5.2.1 Positioning and fixing The HELCON series modules are suitable for “exposed” mounting; to ensure effective heat dissipation, it is necessary to mount them in a vertical position, using the fixing holes provided for this purpose. The following image shows the dislocation of the upper fixing holes, which is realized by means of a metal insert with metric thread M6 (MA pitch). - Page 14 IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN Bottom side view (BOTTOM) In some installations, the support may be subject to considerable vibration, which could damage the device. In this case, it is recommended to use dampers (“silentblock”) made of elastomeric material, whose characteris- tics must be determined on the basis of the magnitude and frequency of the vibrations themselves.
- Page 15 IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN The HELCON 11XX series modules entrust the heat dissipation to an aluminum heatsink mounted on the back of the same. To ensure optimal performance of the same, it is necessary to keep minimum distances during assembly, both from the mounting wall and from nearby objects.
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Page 16: Connections
IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN 5.3 Connections The connectors are located at the bottom. The following image shows the connections available on the bottom of the equipment: Connections Marker Description Main power supply Field bus - input -... -
Page 17: Power Supply - J1
IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN 5.3.1 Power supply - J1 This is the mains supply (2 PH), using the J1 connector (2-pole 1000V 100A male; manufacturer: Ilme, code CX 02 GM). The image and the pinout of the connector are shown below: 400 VAC power supply Marker Signal... -
Page 18: Connection Scheme
5 kA. Such devices could be constituted by fuses, or switches-limiters. Contact SMITEC for information on the sizing of the same. Ver. 1.02... - Page 19 IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN Do not install the device where the expected short-circuit current exceeds 5 kA. Danger of fire and damage to people and property. The use of an inadequate overcurrent protection device could cause it to fail to intervene, with danger for people and things.
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Page 20: Electromagnetic Compatibility
IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN The use of conductors with a section less than the recommended value could cause fire risk and damage to people and things. In many installations multiple modules are used at the same time, in this case it is recommended to distribute the same on the various network phases trying to equalize as much as possible the load on the various phases. - Page 21 IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN The following illustration shows the pinout of the same (the image shows the connector J2, the connector J3 is the same). Polarization FLxIO field bus J2 (input) J3 (output) Signal...
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Page 22: 24Vdc Input Power Supply - J4 Connector
IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN 5.3.3 24VDC input power supply - J4 connector The J4 connector (4 poles, 90° male type M12, polarization A; manufacturer: Phoenix Contact, code 1436589) makes available the input of the external 24V DC power supply. -
Page 23: 24Vdc Power Supply - J5 Connector
IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN 5.3.4 24VDC power supply - J5 connector The J5 connector (4 poles, 90 ° female type M12, A-coded; manufacturer: Phoenix Contact, code 1436564) makes the output of the external 24V DC power supply available. The pinout of the connector is shown in the following image: Polarization 24VDC... -
Page 24: Leds
IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN 5.4 LEDs The device has LED indicators mounted on the logic board fixed inside the electrical cabinet, which with the help of special light guides positioned on the lower part of the HELCON module, inform the user about the sta- tus of the field bus (FLxIO), the power supply line and the operating condition. -
Page 25: Auxiliary Power Supply Status
IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN FLASH 8Hz Communication in error FLxIO master not active: bootloader phase FLxIO master active: active communication The status is distinguishable by observing the status LED on the coupler 5.4.2 Auxiliary power supply status The status of the 24VDC power supply line is signaled by the green LED, marked in this manual with the initials PWR. -
Page 26: Manual Addressing
IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN 5.5.1 Manual addressing In this mode the address of the module must be set using the appropriate rotary switch located on the lower part of the HELCON module; before being able to act on the rotary switch, it is necessary to remove the pro- tective cap of the same, by unscrewing it anticlockwise with the aid of a suitable sized slotted screwdriver. -
Page 27: Automatic Addressing
IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN Decimal Hexadecimal Address 0 must never be used. Since the address is acquired by the module only when the auxiliary voltage is switched on, the setting must be made before powering it, otherwise the variation is ignored until the next power up of the module. -
Page 28: Power Output
IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN 5.6 Power output This is the connector for connecting the lamps. The type of connector differs in the various versions of the mod- ule. 5.6.1 HELCON 1108 Connector female fruit 16 pole 500V 16A with spring connection made of self-extinguishing thermoplastic resin (code N120770, manufacturer: Weidmuller). -
Page 29: Helcon 1110
IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN 5.6.2 HELCON 1110 Connector female 24 pole 500V 16A female with spring connection made of self-extinguishing thermoplastic resin (code CSHF 24, manufacturer: Ilme). Function Pinout PIN 1 Lamp 1... -
Page 30: Operation And Diagnostics
IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN 6 Operation and diagnostics The HELCON 11XX series modules are designed for the control of infrared halogen lamps. Each module al- lows the piloting of 8 (HELCON 1108) or 10 lamps (HELCON 1110), with control of the power level supplied to each lamp. - Page 31 IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN going off for the rest of the half wave; the shutdown occurs at the next passage on 0V as the current flowing inside the TRIAC drops below the minimum value to remain ignited. This cycle therefore repeats itself at each network half-wave.
- Page 32 IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN Ver. 1.02...
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Page 33: Storage
IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN 7 Storage The device and its components can be stored in their original packaging and always in a covered place, even if they are packed. Protect the device against dust and atmospheric agents. Do not stack more than 3 modules, in order to avoid overstretching the package and/or device. -
Page 34: Firmware Upgrade
IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN 8 Firmware upgrade Following significant improvements or additional functionalities, the IR lamp control module can be updated with a more recent firmware version. This operation can be carried out through FLxIO field bus (remote programming); if the master device recog- nizes that the module is programmed with a different FW version as compared to the version loaded in the memory, it automatically re-programmes it. -
Page 35: Maintenance
IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN 9 Maintenance Before carrying out any type of maintenance operation, disconnect power to the device and disconnect all electrical connections. If it is necessary to perform maintenance on the HELCON module, it will be necessary to open the door of the device using the special dedicated key. -
Page 36: Fuse Replacement
IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN 9.1 Fuse replacement Fuse holder door • Safely disconnect the equipment from the power supply. • Open the door with the appropriate key provided. •... - Page 37 IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN • Safely disconnect the equipment from the power supply. • Open the door with the appropriate key provided. • Remove the plexiglass cover to protect the SSR modules using a 4 mm hexagonal key, as shown in the figure below: Unscrew with a 4 mm hexagonal key •...
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Page 38: Periodic Maintenance - Tightening Of The Fuse Holder Terminals And Power Dividers
IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN • Reposition the fixing screws in place; sprinkle the stem of the upper fixing screw (the one that fixes the tab of the electronic component to the fixing plate) with medium-type Loctite 243 type brakes or equivalent. Tight- en the screws with a torque tool to a torque of 1.0 Nm ±... - Page 39 IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN Before tightening all the terminals of the fuse holders, always make sure to remove power supply from the device. Failure to perform maintenance can cause risk of device failure. Ver.
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Page 40: Disposal And Demolition
IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN 10 Disposal and demolition The disposal of this device must be carried out according to the laws in force in the country where it was in- stalled. -
Page 41: Analytical Index
IR lamp control module - HELCON 11XX series - Installation, use and maintenance manual - EN 11 Analytical index Numerics 24VDC ............23, 28 Positioning............13 Power consumption........... 9 Power output ........... 28 Power supply..........9, 17 Accessories............11 Addressing ............24 Assembly ............
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